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NASA NTRS2000

A 3-D Magnetic Analysis of a Linear Alternator For a Stirling Power System

The NASA Glenn Research Center and the Department of Energy (DOE) are developing advanced radioisotope Stirling convertors, under contract with Stirling Technology Company (STC), for space applications. Of critical importance to the successful development of the Stirling convertor for space power applications is the development of a lightweight and highly efficient linear alternator. This paper presents a 3-D finite element method (FEM) approach for evaluating Stirling convertor linear alternators. Preliminary correlations with open-circuit voltage measurements provide an encouraging level of confidence in the model. Spatial plots of magnetic field strength (H) are presented in the region of the exciting permanent magnets. These plots identify regions of high H, where at elevated temperature and under electrical load, the potential to alter the magnetic moment of the magnets exists. This implies the need for further testing and analysis.

Geng, Steven M.↗

NASA NTRS2015

Advanced Stirling Convertor (ASC) Technology Maturation

The Advanced Stirling Convertor (ASC) development effort was initiated by NASA Glenn Research Center (GRC) with contractor Sunpower Inc. to develop high efficiency thermal-to-electric power conversion technology for NASA Radioisotope Power Systems. Early successful performance demonstrations led to the expansion of the project as well as adoption of the technology by the Department of Energy (DOE) and system integration contractor Lockheed Martin Space Systems Company as part of the Advanced Stirling Radioisotope Generator (ASRG) flight project. The ASRG integrates a pair of ASCs to convert the heat from a pair of General Purpose Heat Source (GPHS) modules into electrical power. The expanded NASA ASC effort included development of several generations of ASC prototypes or Engineering Units to help prepare the ASC technology and Sunpower for flight implementation. Sunpower later had two parallel contracts allowing the last of the NASA Engineering Units called ASC-E3 to serve as pathfinders for the ASC-F flight convertors being built for DOE. The ASC-E3 convertors utilized the ASC-F flight specifications and were built using the ASC-F design and process documentation. Shortly after the first ASC-F Pair achieved initial operation, due to budget constraints, the DOE ASRG flight development contract was terminated. NASA continues to invest in the development of Stirling RPS technology including continued production of the ASC-E3 convertors, seven of which have been delivered with one additional unit in production. Starting in FY2015, Stirling Convertor Technology Maturation has been reorganized as an element of the RPS Stirling Cycle Technology Development (SCTD) Project and long-term plans for continued Stirling technology advancement are in reformulation. This paper provides a status on the ASC project, an overview of advancements made in the design and production of the ASC at Sunpower, and a summary of acceptance tests, reliability tests, and tactical tests at NASA GRC that demonstrate the capabilities of the ASC.

radioisotope↗

NASA NTRS2016

Advanced Stirling Convertor (ASC) Technology Maturation

The Advanced Stirling Convertor (ASC) development effort was initiated by NASA Glenn Research Center with contractor Sunpower, Inc., to develop high-efficiency thermal-to-electric power conversion technology for NASA Radioisotope Power Systems (RPSs). Early successful performance demonstrations led to the expansion of the project as well as adoption of the technology by the Department of Energy (DOE) and system integration contractor Lockheed Martin Space Systems Company as part of the Advanced Stirling Radioisotope Generator (ASRG) flight project. The ASRG integrates a pair of ASCs to convert the heat from a pair of General Purpose Heat Source (GPHS) modules into electrical power. The expanded NASA ASC effort included development of several generations of ASC prototypes or engineering units to help prepare the ASC technology and Sunpower for flight implementation. Sunpower later had two parallel contracts allowing the last of the NASA engineering units called ASC-E3 to serve as pathfinders for the ASC-F flight convertors being built for DOE. The ASC-E3 convertors utilized the ASC-F flight specifications and were built using the ASC-F design and process documentation. Shortly after the first ASC-F pair achieved initial operation, due to budget constraints, the DOE ASRG flight development contract was terminated. NASA continues to invest in the development of Stirling RPS technology including continued production of the ASC-E3 convertors, seven of which have been delivered with one additional unit in production. Starting in fiscal year 2015, Stirling Convertor Technology Maturation has been reorganized as an element of the RPS Stirling Cycle Technology Development (SCTD) Project and long-term plans for continued Stirling technology advancement are in reformulation. This paper provides a status on the ASC project, an overview of advancements made in the design and production of the ASC at Sunpower, and a summary of acceptance tests, reliability tests, and tactical tests at NASA Glenn that demonstrate the capabilities of the ASC.

Stirling cycle↗

NASA NTRS2014

Advanced Stirling Convertor (ASC) Development for NASA RPS

Sunpower's Advanced Stirling Convertor (ASC) initiated development under contract to the NASA Glenn Research Center (GRC) and after a series of successful demonstrations, the ASC began transitioning from a technology development project to flight development project. The ASC has very high power conversion efficiency making it attractive for future Radioisotope Power Systems (RPS) in order to make best use of the low plutonium-238 fuel inventory in the U.S. In recent years, the ASC became part of the NASA-Department of Energy Advanced Stirling Radioisotope Generator (ASRG) Integrated Project. Sunpower held two parallel contracts to produce ASC convertors, one with the Department of Energy/Lockheed Martin to produce the ASC-F flight convertors, and one with NASA GRC for the production of ASC-E3 engineering units, the initial units of which served as production pathfinders. The integrated ASC technical team successfully overcame various technical challenges that led to the completion and delivery of the first two pairs of flight-like ASC-E3 by 2013. However, in late Fall 2013, the DOE initiated termination of the Lockheed Martin ASRG flight development contract driven primarily by budget constraints. NASA continues to recognize the importance of high efficiency ASC power conversion for RPS and continues investment in the technology including the continuation of ASC-E3 production at Sunpower and the assembly of the ASRG Engineering Unit #2. This paper provides a summary of ASC technical accomplishments, overview of tests at GRC, plans for continued ASC production at Sunpower, and status of Stirling technology development.

Power Efficiency↗

NASA NTRS1987

Advanced Gas Turbine (AGT) Technology Development Project, ceramic component developments

The ceramic component technology development activity conducted by Standard Oil Engineered Materials Company while performing as a principal subcontractor to the Garrett Auxiliary Power Division for the Advanced Gas Turbine (AGT) Technology Development Project (NASA Contract DEN3-167) is summarized. The report covers the period October 1979 through July 1987, and includes information concerning ceramic technology work categorized as common and unique. The former pertains to ceramic development applicable to two parallel AGT projects established by NASA contracts DEN3-168 (AGT100) and DEN3-167 (AGT101), whereas the unique work solely pertains to Garrett directed activity under the latter contract. The AGT101 Technology Development Project is sponsored by DOE and administered by NASA-Lewis. Standard Oil directed its efforts toward the development of ceramic materials in the silicon-carbide family. Various shape forming and fabrication methods, and nondestructive evaluation techniques were explored to produce the static structural components for the ceramic engine. This permitted engine testing to proceed without program slippage.

Teneyck, M. O.↗

NASA NTRS1995

Variable speed generator application on the MOD-5A 7.3 mW wind turbine generator

This paper describes the application of a Scherbiustat type variable speed subsystem in the MOD-5A Wind Turbine Generator. As designed by General Electric Company, Advanced Energy Programs Department, under contract DEN3-153 with NASA Lewis Research Center and DOE, the MOD-5A utilizes the subsystem for both starting assistance in a motoring mode and generation in a controlled airgap torque mode. Reactive power control is also provided. The Scherbiustat type arrangement of a wound rotor machine with a cycloconverter in the rotor circuit was selected after an evaluation of variable speed technologies that followed a system evaluation of drivetrain cost and risk. The paper describes the evaluation factors considered, the results of the evaluations and summarizes operating strategy and performance simulations.

Barton, Robert S.↗

NASA NTRS1989

Comparison of conceptual designs for 25 kWe advanced Stirling conversion systems for dish electric application

The Advanced Stirling Conversion System (ASCS) Project is managed by NASA Lewis Research Center through a cooperative interagency agreement with DOE. Conceptual designs for the ASCS's were completed under parallel contracts in 1987 by Mechanical Technology Inc. (MTI) of Latham, NY, and Stirling Technology Company (STC) of Richland, WA. Each design features a free-piston Stirling engine, a liquid metal heat pipe receiver, and a means to provide about 25 kW of electric power to a utility grid while meeting DOE's long term performance and cost goals. An independent assessment showed that both designs are manufacturable and have the potential to easily meet DOE's long term cost goals.

Shaltens, Richard K.↗

NASA NTRS1989

Comparison of conceptual designs for 25 kWe advanced Stirling conversion systems for dish electric applications

Shaltens, Richard K.↗

NASA NTRS1986

Advanced Gas Turbine (AGT) Technology Development Project annual report

This report is the tenth in a series of Technical Summary reports for the Advanced Gas Turbine (AGT) Technology Development Project, authorized under NASA Contract DEN3-167, and sponsored by the Department of Energy (DOE). This report was prepared by Garrett Turbine Engine Company, A Division of the Garrett Corporation, and includes information provided by Ford Motor Company, the Carborundum Company, and AiResearch Casting Company. The Project is administered by Mr. Thomas N. Strom, Project Manager, NASA-Lewis Research Center, Cleveland, Ohio. This report covers plans and progress for the period July 1, 1984 through June 30, 1985.

Source record↗

NASA NTRS1987

Advanced Gas Turbine (AGT) Technology Development Project

This report is the eleventh in the series of Technical Summary reports for the Advanced Gas Turbine (AGT) Technology Development Project, authorized under NASA Contract DEN3-167, and sponsored by the Department of Energy (DOE). This report was prepared by Garrett Turbine Engine Company, A Division of the Garrett Corporation, and includes information provided by Ford Motor Company, the Standard Oil Company, and AiResearch Casting Company. This report covers plans and progress for the period July 1, 1985 through June 30, 1986. Technical progress during the reported period was highlighted by the 85-hour endurance run of an all-ceramic engine operating in the 2000 to 2250 F temperature regime. Component development continued in the areas of the combustion/fuel injection system, regenerator and seals system, and ceramic turbine rotor attachment design. Component rig testing saw further refinements. Ceramic materials showed continued improvements in required properties for gas turbine applications; however, continued development is needed before performance and reliability goals can be set.

Source record↗

NASA NTRS1995

Control system design for the MOD-5A 7.3 mW wind turbine generator

This paper provides descriptions of the requirements analysis, hardware development and software development phases of the Control System design for the MOD-5A 7.3 mW Wind Turbine Generator. The system, designed by General Electric Company, Advanced Energy Programs Department, under contract DEN 3-153 with NASA Lewis Research Center and DOE, provides real time regulation of rotor speed by control of both generator torque and rotor torque. A variable speed generator system is used to provide both airgap torque control and reactive power control. The wind rotor is designed with segmented ailerons which are positioned to control blade torque. The central component of the control system, selected early in the design process, is a programmable controller used for sequencing, alarm monitoring, communication, and real time control. Development of requirements for use of aileron controlled blades and a variable speed generator required an analytical simulation that combined drivetrain, tower and blade elastic modes with wind disturbances and control behavior. An orderly two phase plan was used for controller software development. A microcomputer based turbine simulator was used to facilitate hardware and software integration and test.

Barton, Robert S.↗

NASA NTRS1984

SP-100 space nuclear power system

A baseline design concept for a 100 kWe nuclear reactor space power system is described. The concept was developed under contract from JPL as part of a joint program of the DOE, DOD, and NASA. The major technical and safety constraints influencing the selection of reactor operating parameters are discussed. A lithium-cooled compact fast reactor was selected as the best candidate system. The material selected for the thermoelectric conversion system was silicon germanium (SiGe) with gallium phosphide doping. Attention is given to the improved safety of the seven in-core control rod configuration.

Given, R. W.↗

NASA NTRS1997

Development of Large Area Emulsion Chamber Methods with a Super Conducting Magnet for Observation of Cosmic Ray Nuclei from 1 GeV to 1,000 TeV (Emulsion Techniques)

The research developed the fundamental techniques of the emulsion chamber methods that permit measurements of the composition and energy spectra of cosmic rays at energies ranging from 1 GeV/n to over 1,000 TeV/n. The research program consisted of exploring new principles and techniques in measuring very high energy cosmic nuclei with large-area emulsion chambers for high statistics experiments. These tasks have been accomplished and their use was essential in successful analysis of the balloon-borne emulsion chamber experiments up to 10(exp 14) eV. It also provided the fundamental technologies for designing large-area detectors that are aimed at measuring the composition at above 1015 eV region. The latter is now partially succeeded by a NASA Mission Concept, Advanced Cosmic Composition Experiments on the Space Station (ACCESS). The cosmic ray group at the University of Alabama in Huntsville has performed technological R & D as well as contributing to the Japanese-American-Emulsion-Chamber-Experiments (JACEE) Collaboration with the regular data analysis. While primary research support for other institutions' efforts in the JACEE experiments came from NSF and DOE, primary support for the University of Alabama in Huntsville was this contract. Supplemental tasks to standardize the data base and hardware upgrades (automatized microscope) had this institutions cooperation. Investigation of new techniques in this program consisted of development of a fast calorimetry, magnetic/scattering selection of high momentum tracks for a pairmeter, and high statistics momentum measurements for low energy nuclei (E < 1 TeV/n). The highest energy calorimetry and a pairmeter have been considered as strawman instruments by the GOAL (Galactic Origin and Acceleration Limit) proposal of the NASA Cosmic Ray Working Group for long- duration balloon flights. We accomplished the objectives of the GOAL program with three circumpolar, Antarctic JACEE balloon flights during 1992 - 1994.

Takahashi, Yoshiyuki↗

NASA NTRS2004

Overview 2003 of NASA Multi-D Stirling Convertor Code Development and DOE and NASA Stirling Regenerator R and D Efforts

This paper win report on continuation through the third year of a NASA grant for multi-dimensional Stirling CFD code development and validation; continuation through the third and final year of a Department of Energy, Golden Field Office (DOE), regenerator research effort and a NASA grant for continuation of the effort through two additional years; and a new NASA Research Award for design, microfabrication and testing of a "Next Generation Stirling Engine Regenerator." Cleveland State University (CSU) is the lead organization for all three efforts, with the University of Minnesota (UMN) and Gedeon Associates as subcontractors. The Stirling Technology Company and Sun power, Inc. acted as unfunded consultants or participants through the third years of both the NASA multi-D code development and DOE regenerator research efforts; they win both be subcontractors on the new regenerator microfabrication contract.

Tew, Roy↗

NASA NTRS2004

Overview 2003 of NASA Multi-D Stirling Convertor Development and DOE and NASA Stirling Regenerator R and D Efforts

This paper will report on (1) continuation through the 3rd year of a NASA grant for multi-dimensional Stirling CFD code development and validation, (2) continuation through the 3rd and final year of a Department of Energy, Golden Field Office (DOE) regenerator research effort. Results of the NASA multi-D code development effort and the DOE regenerator research efforts will be summarized. Early results and planning for the new regenerator microfabrication contract will also be discussed.

Twe, Roy↗

NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA Glenn Research Center

The Thermal Energy Conversion Branch at NASA Glenn Research Center (GRC) is supporting the development of high-efficiency power convertors for use in Radioisotope Power Systems (RPS). Significant progress was made towards such a system that utilized Stirling conversion during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was cancelled in 2013 by the Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton designs. The technology development contracts each consist of up to three phases: Design, Fabricate, and Test. As of May 2018, all contracts have completed the Design Phase, and each underwent a design review with an independent review board. Three of the contracts are planned to execute the Phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, NASA GRC is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating several convertors from previous development projects which have similarities and relevance to current contract designs. Four of which are flexure-bearing based, and another six are gas-bearing based. One of the flexure-bearing convertors has accumulated over 110,000 hours of operation, and holds the current record for maintenance-free heat-engine run-time. Another flexure-bearing convertor was recently manually shutdown after 105,620 hours of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of runtime on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Amongst the gas-bearing convertors, the longest running unit has accumulated over 70,000 hours of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously, for which the longest runtime has reached 28,000 hours.

Oriti, Salvatore M.↗

NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA GRC

The Thermal Energy Conversion Branch at NASA Glenn Research Center (GRC) is supporting the development of high-efficiency power convertors in support of Radioisotope Power System (RPS) development. Significant progress was made towards such a system that utilized Stirling conversion machines during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was cancelled in 2013 by the Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This new effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton designs. The technology development contracts each consist of up to three phases: Design, Fabricate, and Test. As of May 2018, all contracts have completed the Design Phase, and each underwent a design review with an independent review board. Two of the contracts have been awarded the Phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, NASA GRC is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating 10 convertors from previous development projects. Four of which are flexure-bearing based, and the other six are gas-bearing based. One of the flexure-bearing convertors has accumulated over 110,000 hours of operation, and holds the current maintenance-free heat-engine run-time record. Another flexure-bearing convertor was recently manually shutdown after 105,620 hours of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of runtime on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Amongst the gas-bearing convertors, the longest running unit has accumulated over 70,000 hours of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously, for which the longest runtime has reached 26,000 hours.

Oriti, Salvatore↗

NASA NTRS2018

Dynamic Power Convertor Development for Radioisotope Power Systems at NASA Glenn Research Center

The Thermal Energy Conversion Branch at NASA Glenn Research Center is supporting the development of high-efficiency power convertors for use in radioisotope power systems (RPS). Significant progress was made toward such a system that utilized Stirling conversion during the 2001 to 2015 timeframe. Flight development of the Advanced Stirling Radioisotope Generator (ASRG) was canceled in 2013 by the U.S. Department of Energy (DOE) and NASA Headquarters primarily due to budget constraints, and the Advanced Stirling Convertor (ASC) technology contract was subsequently concluded in 2015. A new chapter of technology development has recently been initiated by the NASA RPS Program. This effort is considering all dynamic power convertor options, such as Stirling and Brayton cycles. Four convertor development contracts supporting this effort were awarded in 2017. The awarded contracts include two free-piston Stirling, one thermoacoustic Stirling, and one turbo-Brayton design. The technology development contracts each consist of up to three phases: design, fabrication, and test. As of May 2018, all contracts have completed the design phase, and each underwent a design review with an independent review board. Three of the contracts are planned to execute the phase 2 option for fabrication. Convertors manifesting from these development efforts will then undergo independent validation and verification (IV and V) at NASA facilities, which will consist of convertor performance and RPS viability demonstrations. Example tests include launch vibration simulation, performance mapping over the environmental temperature range, and static acceleration exposure. In parallel with this renewed development effort, Glenn is still demonstrating free-piston Stirling convertor technology using assets from previous projects. The Stirling Research Laboratory (SRL) is still operating several convertors from previous development projects, which have similarities and relevance to current contract designs. Four of these are flexure-bearing based and another six are gas bearing based. One of the flexure-bearing convertors has accumulated over 110,000 h of operation and holds the current record for maintenance-free heat-engine run time. Another flexure-bearing convertor was recently manually shut down after 105,620 h of operation, then disassembled and inspected. This inspection produced a wealth of information about the effects of this amount of run time on the technology's components. One of the engineering unit flexure-bearing convertors recently underwent a launch simulation vibration test, a static acceleration exposure up to 20 g, and was then placed on extended operation. Among the gas-bearing convertors, the longest running unit has accumulated over 70,000 h of operation. Four high-fidelity gas-bearing convertors from the ASRG project are still operating continuously for which the longest run time has reached 28,000 h.

Oriti, Salvatore M.↗